Wavy shaped potato sticks

ABSTRACT

A grate for use in forming potato stick products having a wavy cross-sectional shape is provided. The grate includes a plurality of alternating convex segments and concave segments extending in a repeating pattern along a length of the grate. A plurality of spaced apart teeth extends from the plurality of convex segments and the plurality of concave segments. A distance between the spaced apart teeth defines a width of the potato stick products.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.61/779,129, filed Mar. 13, 2013, the entire disclosure of which ishereby incorporated herein by reference.

BACKGROUND

Potato chips are a common snack product. Potato chips can have flatsurfaces that can be formed by urging a potato through flat bladesarranged in a parallel orientation, thereby forming a flat slice of thepotato. The potato slice can be fried until it is crunchy, therebyproviding the potato chip for consumption. Snack manufacturers providepotato chips in a variety of styles, and in a multitude of flavors.

Other potato chips can have wavy (also called “marcelled”) shapes.Marcelled style potato chips have a repeating series of peaks andtroughs. Marcelled style potato chips can be manufactured using potatoslicing machines fitted with a plurality of blades having cooperatingwavy cutting edges.

Another snack product, related to potato chips, is known as a potatostick. Potato sticks are generally narrow, stick-like, thin strips of apotato. Typically, potato sticks measure less than 0.5 inches in widthand approximately 2.0 inches to 5.0 inches in length. Potato sticks aremanufactured in a manner similar to that of potato chips. Potatoes areurged through flat blades arranged in a parallel orientation, therebyforming a flat slice of potato. The resulting flat slice of potato issubsequently urged though grates, thereby cutting the flat slice ofpotato into sticklike strips.

Conventional flat potato sticks are undesirably fragile, and can breakeasily during storage and transport. Flat potato sticks are also notwell suited for receive dips. With a thicker dip, in particular, flatpotato sticks are known to break off and leave behind broken portions inthe dip container.

There is a continuing need for a potato stick product having a shapethat is more robust for storage and transport. Desirably, the potatostick product is configured to receive dips, and particularly thickerdips, without significant breakage.

SUMMARY

In concordance with the instant disclosure, a potato stick producthaving a shape that is more robust for storage and transport, and whichis configured to receive dips, and particularly thicker dips, withoutsignificant breakage, is surprisingly discovered.

In one embodiment, there is provided a grate for use in forming potatostick products having a wavy cross-sectional shape. The grate includes aplurality of alternating convex segments and concave segments extendingin a repeating pattern along a length of the grate. A plurality ofspaced apart teeth extends from the plurality of convex segments and theplurality of concave segments. A distance between the spaced apart teethdefines a width of the potato stick products.

In another embodiment, there is provided a cutting head assembly for usein forming potato stick products having a wavy cross-sectional shape.The cutting head assembly includes a blade holder having a plurality ofalternating convex segments and concave segments. A blade is nested withthe blade holder. The blade has a plurality of alternating convexsegments and concave segments with a cutting edge configured to extendbeyond the convex segments and concave segments of the blade holder. Thecutting edge of the blade is further configured to form the wavycross-sectional shape of the potato sticks. A grate is nested with theblade. The grate has a plurality of alternating convex segments andconcave segments configured to align with the plurality of alternatingconvex segments and concave segments of the blade. The grate has aplurality of spaced apart teeth. A distance between the spaced apartteeth defines a width of the potato stick products. A clamp isconfigured to secure the blade and the grate to the blade holder.

In a further embodiment, there is also provided a method of formingpotato stick products having a wavy cross-sectional shape. The methodincludes the steps of providing a blade having a plurality of convexsegments and concave segments, each having cutting edges, nesting agrate with the blade, the grate having a plurality of convex segmentsand concave segments, in the nested position the plurality of convexsegments and concave segments of the blade substantially align with theconvex and concave segments of the grate, the grate including aplurality of spaced apart teeth, a distance between the spaced apartteeth defines a width of the potato sticks and urging one or morepotatoes through the nested blade, grate and teeth such that the wavypotato sticks are formed.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, as well as other objects and advantages of the disclosure,will become readily apparent to those skilled in the art from readingthe following detailed description, particularly when considered in thelight of the accompanying drawings in which:

FIG. 1 is a top plan view of a wavy potato stick product according toone embodiment of the present disclosure;

FIG. 2 is an end view, in elevation, of the wavy potato stick productshown in FIG. 1;

FIG. 3 is a perspective view of a potato slicing machine having aplurality of cutting head assemblies for producing the wavy potato stickproduct shown in FIG. 1;

FIG. 4a is an exploded perspective view of a blade and grate assembly ofthe potato slicing machine of FIG. 3, and illustrating a blade and agrate having a plurality of teeth; and

FIG. 4b is a perspective view of an assembled blade and grate assemblyof FIG. 4 a.

DETAILED DESCRIPTION

The present disclosure will now be described with occasional referenceto the specific embodiments. This disclosure may, however, be embodiedin different forms and should not be construed as limited to theembodiments set forth herein. Rather, these embodiments are provided sothat this disclosure will be thorough and complete, and will fullyconvey the scope of the disclosure to those skilled in the art.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this disclosure belongs. The terminology used in thedescription herein is for describing particular embodiments only and isnot intended to be limiting. As used in the description and the appendedclaims, the singular forms “a,” “an,” and “the” are intended to includethe plural forms as well, unless the context clearly indicatesotherwise.

Unless otherwise indicated, all numbers expressing quantities ofdimensions such as length, width, height, and so forth as used in thespecification and claims are to be understood as being modified in allinstances by the term “about.” Accordingly, unless otherwise indicated,the numerical properties set forth in the specification and claims areapproximations that may vary depending on the desired properties soughtto be obtained in embodiments of the present disclosure. Notwithstandingthat the numerical ranges and parameters setting forth the broad scopeof the disclosure are approximations, the numerical values set forth inthe specific examples are reported as precisely as possible. Anynumerical values, however, inherently contain certain errors necessarilyresulting from error found in their respective measurements.

In accordance with embodiments of the instant disclosure, apparatusmethods for forming potato stick products having a novel wavy shape areprovided. Generally, the apparatus and methods include a blade matedwith a grate, with the blade configured to impart a wavy pattern to thethin slices of potato. The grate includes a plurality of teethconfigured to cut the thin slices of potato into strips, with each striphaving the novel wavy pattern. It will be understood the term “potatostick products”, as used herein, is defined to mean any product formedfrom potato and having a generally thin stick form. The term “wavy” asused herein, is defined to mean any shape having one or more peaks andtroughs.

Referring now to FIGS. 1 and 2, there is illustrated generally a portionof a potato stick product (hereafter “product”) at 10. Referring firstto FIG. 1, the product has a width W and a length L. In the illustratedembodiment, the width W is in a range of about 0.2 inches to about 0.4inches and the length L is in a range of from about 1.0 inch to about6.0 inches. However, it should be appreciated that in other embodiments,the width W can be less than about 0.2 inches or more than about 0.4inches, and the length L can be less than about 1.0 inch or more thanabout 6.0 inches. In still other embodiments, the width W can beexpressed as a function of the length L. In these embodiments, width Wcan be in a range of about 6% to about 15% of the length L. However, itshould be appreciated that the width W can be less than 6% of the lengthL or more than 15% of the length L, as desired.

With reference to FIG. 2, an end view of the product 10 is illustrated.The product 10 has a wavy cross-sectional shape that includes a peak 12and a trough 14. The peak 12 and the trough 14 cooperate to form an “S”cross-sectional shape along an axis A-A extending the width W of theproduct 10. While the illustrated embodiment shows the product 10 ashaving an “S” cross-sectional shape, in other embodiments the product 10can have other cross-sectional shapes, such as the non-limiting exampleof a “W” cross-sectional shape. Further, while the illustratedembodiment shows the product 10 as having a single peak 12 and a singletrough 14, it should be appreciated that in other embodiments, theproduct 10 can have more than one peak and more than one trough.

Referring again to FIG. 2, the product 10 has a thickness T. In theillustrated embodiment, the thickness T is in a range of from about 0.04inches to about 0.10 inches. Alternatively, the thickness T of theproduct 10 can be less than about 0.04 inches or more than about 0.10inches. In the illustrated embodiment, the thickness T of the product 10is substantially constant along the width W. In other embodiments, thethickness T can vary as desired along the width W.

As shown in FIG. 2, the peaks 12 have a height HP as measured from theaxis A-A and the troughs 14 have a height HT as measured from the axisA-A. The peaks 12 have a width WP and the troughs 14 have a second widthWT. The heights HP, HT and the widths WP, WT will be discussed in moredetail below.

The product 10 shown in FIGS. 1 and 2 is provided in a raw (precooked)shape and form. However, it should be understood that the product 10will have a substantially similar shape and form after the product 10 isfully cooked, for example, through a frying process or a baking processas is known in the art.

Referring now to FIG. 3, an apparatus 20 configured to form potatostrips is illustrated generally at 20. The apparatus 20 includes arotatable impeller 22 positioned within a stationary framework 24. Theimpeller 22 includes a base 26. A plurality of forms 28 are spaced apartalong an outer edge 30 of the base 26. The forms 28 are attached to thebase 26, such that the base 26 and the forms 28 rotate together aboutbase center point 32.

The framework 24 shown in FIG. 3 includes a plurality of spaced apartcutting head assemblies 34. As will be discussed in more detail below,each cutting head assembly 34 includes a blade and grate assembly 38,configured to slice potatoes 36, thereby forming the product 10.

In operation, raw potatoes 36 are loaded into the apparatus 20 as theimpeller 22 is rotated. Centrifugal force urges the potatoes 36 to theouter edge 30 of the base 26, where the potatoes contact the forms 28.The potatoes 36 are repeatedly guided by the forms 28 into contact withthe blade and grate assemblies 38. The blade and grate assemblies 38simultaneously cut the potatoes 36 into thin slices and cut the thinslices into narrow strips, thereby forming the desired potato stickproduct 10. The cutting head assemblies 34 can be adjusted to vary thethickness T of the product 10 as desired.

Referring now to FIG. 4a , an exploded view of a blade and grateassembly 38 is illustrated. The blade and grate assembly 38 includes ablade holder 40, a blade 42, a grate 44, a clamp 46 and a plurality offasteners 48. The blade holder 40 has a first segment 50 and a secondsegment 52. The first segment 50 has a plurality of alternating convexsegments 54 and concave segments 56 disposed transversely along an axisB-B extending a length of the blade holder 40. As will be explained inmore detail below, the pattern of alternating convex segments 54 andconcave segments 56 of the first segment 50 of the blade holder 40 isconfigured to correspond to a similar pattern of convex segments andconcave segments forming the blade 42.

The first segment 50 of the blade holder 40 has a depth DBH. The depthDBH will be discussed in more detail below.

Referring again to FIG. 4a , the second segment 52 of the blade holder40 is attached to the first segment 50 and forms an upper surface 58.The second segment 52 further includes apertures 60 a, 60 b. As will beexplained in more detail below, the upper surface 58 and the apertures60 a, 60 b are used to secure the blade 42, grate 44 and clamp 46 to theblade holder 40.

With reference to FIG. 4a , the blade 42 includes a plurality ofrepeating convex segments 62 and concave segments 64 disposedtransversely along a transverse axis C-C of the blade 42, therebyforming a marcelled cross-sectional shape. As discussed above, therepeating convex segments 62 and concave segments 64 of the blade 42 areconfigured to generally correspond to, and align with, the repeatingconvex segments 54 and concave segments 56 of the blade holder, suchthat the blade 42 can nest tightly against the first segment 50 of theblade holder 40. In the tightly nested position, there is no appreciablespace between the blade 42 and the blade holder 40. Any desired quantityof convex segments 62 and concave segments 64 can be disposed along alength of the blade 42. While the embodiment illustrated in FIG. 4aincludes convex segments 62 and concave segments 64 configured to formthe marcelled cross-sectional shape, it is contemplated that the blade42 can have other cross-sectional shapes.

As shown in FIG. 4a , the convex segments 62 of the blade 42 have aheight HCV, as measured from the axis C-C, and the concave segments 64have a height HCC, as measured from the axis C-C. The height HCV of theconvex segments 62 is configured to form the height HP of the peaks 12of the product 10, and the height HCC of the concave segments 64 isconfigured to form the height HT of the troughs 14 of the product 10 asshown in FIG. 2. In the illustrated embodiment, the heights HCV, HCC areequal. However, a skilled artisan may select different heights HCV, HCC,as desired.

Referring again to FIG. 4a , the convex segments 62 have a width WCV andthe concave segments 64 have a width WCC. The width WCV of the convexsegments 62 is configured to form the width WP of the peaks 12 of theproduct 10, and the width WCC of the concave segments 64 is configuredto form the widths WT of the troughs 14 of the product 10 as shown inFIG. 2. In the illustrated embodiment, the widths WCV, WCC are equal.However, in other embodiments, the widths WCV, WCC may be different.

The blade 42 has an edge 66 configured to slice potatoes. In theillustrated embodiment, the edge 66 is configured as a double edgedrazor. Alternatively, the edge 66 can have other configurations, such asfor example, a single edge, sufficient to slice potatoes.

Referring again to FIG. 4a , the blade 42 has a depth DB. In theillustrated embodiment, the depth DB of the blade is longer than thedepth DBH of the first segment 50 of the blade holder 40, such that in anested position, the edge 66 of the blade 42 extends beyond the firstsegment 50 of the blade holder 40. However, it is contemplated that theblade 42 can have any desired depth DB, sufficient that in a nestedposition, the edge 66 of the blade 42 extends beyond the first segment50 of the blade holder 40.

In the embodiment illustrated in FIG. 4a , the blade 42 is formed from ametallic material, such as for example, carbon steel. However, in otherembodiments, the blade 42 can be formed from other materials, such asfor example, rigid polymeric materials, sufficient to slice potatoes.Further, the blade 42 can have any desired surface coating such as, forexample, a low-friction coating, or any desired surface texture such asthe non-limiting example of a micro-grooved surface texture.

Referring again to FIG. 4a , the grate 44 includes a first segment 68and a second segment 70. The first segment 68 includes a plurality ofalternating convex segments 72 and concave segments 74 disposedtransversely along a transverse axis D-D of the grate 44. In theillustrated embodiment, the convex segments 72 and concave segments 74of the grate 44 have similar heights and widths of the convex segments62 and concave segments 64 of the blade 42, thereby allowing the firstsegment 68 of the grate 44 to align and nest with the blade 42. In otherembodiments, the convex segments 72 and concave segments 74 of the grate44 can have other shapes, dimensions and characteristics sufficient toallow the first segment 68 of the grate 44 to nest with the blade 42.

With renewed reference to FIG. 4a , the second segment 70 of the grate44 includes a plurality of spaced apart teeth 76 extending from theconvex segments 72 and the concave segments 74. In the illustratedembodiment, the teeth 76 are aligned in planes that are substantiallyperpendicular to the transverse axis D-D. However, in other embodiments,the teeth 76 can have other desired alignments relative to thetransverse axis D-D.

The teeth 76 have an edge 78 configured to slice potatoes. In theillustrated embodiment, the edge 78 is configured as a double edgedrazor. Alternatively, the edge 78 can have other configurations, such asfor example, a single edge, sufficient to slice potatoes.

Referring again to embodiment illustrated in FIG. 4a , the edge 78 isaligned to be substantially perpendicular to the transverse axis D-D.However, in other embodiments, the edge 78 can be aligned in otherorientations relative to the transverse axis D-D.

Referring again to FIG. 4a , and as discussed above, the teeth 78 arespaced apart along the length of the gate 44 an equal distance DS fromeach other. In the illustrated embodiment, the distance DS issubstantially the same as the width W of the product 10 as shown inFIG. 1. It is contemplated that the distance DS between teeth 60 mayvary as desired.

Referring again to the embodiment shown in FIG. 4a , the teeth 76 have asubstantially rectangular shape. Alternatively, the teeth 76 can haveany desired shape, including the non-limiting shape of a triangle,sufficient that an edge 78 of the teeth is configured for forming theproduct 10.

Referring again to FIG. 4a , the teeth 78 are disposed along the lengthof the grate 44 such that the resulting product 10 comprises at leastone peak 12 and at least one trough 14. Positioning of the teeth 78 inthese locations allows the grate 44 to slice the potatoes such as toform the shape of the product 10 shown in FIGS. 1 and 2. It should beunderstood that the teeth 78 can be disposed in a substantiallyidentical manner along the length of the grate 44, such that each of theteeth 78 can be disposed at the vertex of each convex segment 72 or inanother manner. Additionally, it should be understood that the teeth 78can also be spaced apart at varying distances.

In the embodiment illustrated in FIG. 4a , the grate 44 and the teeth 76are formed as a unitary structure. However, it is within thecontemplation of this disclosure that the teeth 76 can be formed asdiscrete members and later added to the grate 44.

Referring again to the embodiment illustrated in FIG. 4a , the grate 44is formed from a metallic material, such as for example, carbon steel.However, in other embodiments, the grate 44 can be formed from othermaterials, such as for example, polymeric materials, sufficient to slicepotatoes. Further, the grate 44 can have any desired surface coating,such as for example, a low-friction coating or any desired surfacetexture, such as the non-limiting example of a micro-grooved surfacetexture.

Referring again to FIG. 4a , the clamp 46 includes a first segment 80and a second segment 82. The first segment 80 has a plurality ofalternating convex segments 84 and concave segments 86 disposedtransversely along an axis E-E extending a length of the clamp 46. Thepattern of the alternating convex segments 84 and concave segments 86 ofthe first segment 80 of the clamp 46 is configured to correspond to thesimilar patterns of convex segments and concave segments forming theblade 42 and the first segment 68 of the grate 44.

Referring again to FIG. 4a , the second segment 82 of the clamp 46 isattached to the first segment 80 and forms a lower surface 88. Thesecond segment 82 further includes apertures 90 a, 90 b. As will beexplained in more detail below, the lower surface 88 and the apertures90 a, 90 b are used to secure the blade 42, grate 44 and clamp 46 to theblade holder 40.

With renewed reference to FIG. 4a , the plurality of fasteners 48 areconfigured to extend through the apertures 90 a, 90 b of the clamp andengage the apertures 60 a, 60 b of the blade holder 40. In theillustrated embodiment, the fasteners 48 are threaded bolts and theapertures 60 a, 60 b are threaded holes. Alternatively, otherstructures, mechanisms and devices, such as for example can be used tosecure the blade 42, grate 44 and clamp 46 to the blade holder 40.

Referring now to FIG. 4b , a view of the blade and grate assembly 38 isillustrated. The blade holder 40 having the first segment 50 and thesecond segment 52 is positioned on the bottom of the assembly 38. Next,the blade 42 is nested with the first segment 50 of the blade holder 40such that the convex and concave segments 62, 64 of the blade 42 alignwith the convex and concave segments 54, 56 respectively of the bladeholder 40. Next, the grate 44 is positioned such that the convex andconcave segments 72, 74 of the first segment 68 of the grate 44 arealigned and nested with the convex and concave segments 62, 64 of theblade 42. Next, the first segment 80 of the clamp 46 is nested with thefirst segment 68 of the grate 44 such that the convex and concavesegments 84, 86 of the clamp 46 align with the convex and concavesegments 72, 74 respectively of the grate 44. In this position, thelower surface 88 of the clamp 46 seats against the upper surface 58 ofthe blade holder 40. Finally, the fasteners 48 are configured to providea compressive force to the assembled clamp 46, grate 44, blade 42 andblade holder 40, such as to secure the assembly 38.

Referring again to FIG. 4b , it can be seen that in an assembledposition, the edge 66 of the blade 42 extends beyond the first segment50 of the blade holder 40. The edge 66 of the blade 42 is arranged inthis manner to allow the blade 42 to cut the potatoes (not shown) intothin slices. It can also be seen that in an assembled position, theteeth 78 of the grate 44 are positioned to cut the thin slices of potatointo thin strips of product 10 having the desired wavy cross-sectionalshape as shown in FIGS. 1 and 2.

Referring again to FIG. 4b , the blade and grate assembly 38 can be usedin concordance with any automatic or high speed production line or inconcordance with any other slicing machine, device, or apparatus.Additionally, the blade and grate assembly 38 advantageously results ineasy removal of the blade 42 and grate 44 in order to efficientlyinterchange production of marcelled potato chips to the wavy potatostick product, and vice versa.

In operation, the method of manufacturing the product 10 includes thefollowing steps: first a blade with a cutting edge having a marcelledshape is nested with a blade holder. The blade is configured to cutpotatoes into thin slices. Next, a grate having a plurality of offsetteeth is nested with the blade. The teeth are configured to cut thepotato slices into potato strips. Next, a clamp and fasteners areconfigured to secure the blade holder, blade and grate into the bladeand grate assembly. In a next step, the blade and grate assembly arefitted into a suitable slicing machine, device, or apparatus. Finally,the slicing machine is operated to feed a potato through the blade andgrate assembly thereby forming potato strips having a novel wavy shape.

It should be appreciated that other food products can be employed tocreate marcelled slices of the respective food product, such as forexample, other vegetables or fruit. As examples, carrots can be used tocreate marcelled carrot sticks or an eggplant can be used to createmarcelled eggplant sticks. Processed food stuffs may also be sliced intothe wavy stick product using the system and method of the presentdisclosure.

Referring again to FIGS. 1 and 2, the product 10 advantageously has anappealing shape and overall appearance, and is also surprisinglydimensionally stable for purposes of packaging and transporting to theconsumer.

Advantageously, the potato stick product 10 having the shape a describedhereinabove is believed to be more robust than conventional potato stickproducts, which facilitates storage and transport of the product 10. Theproduct 10 is also believed to exhibit less breakage when receivingdips, and particularly thicker dips, in comparison to flat potato stickproducts known in the art.

The principle and mode of operation of the apparatus and method forforming potato stock products having a wavy shape have been described incertain embodiments. However, it should be noted that the apparatus andmethod for forming potato stock products may be practiced otherwise thanas specifically illustrated and described without departing from itsscope.

What is claimed is:
 1. A grate for use in forming potato stick productshaving a wavy cross-sectional shape, the grate having a single,one-piece, unitary body comprising: a plurality of alternating convexsegments and concave segments extending in a repeating pattern on anaxis oriented along a length of the grate and defining a front side anda rear side; and a plurality of spaced apart teeth extending in anupward direction and not in a downward direction from the plurality ofconvex segments and the plurality of concave segments, wherein each ofthe teeth has a fixed edge, a cutting edge, and an upper edge, the fixededge coupled to one of the convex segments and the concave segments atthe front side, the cutting edge being a free end disposed opposite thefixed edge, and the upper edge being a free end arranged between thefixed edge and the cutting edge, and each of the teeth is furtheraligned in one of a plurality of planes that are oriented substantiallyperpendicular to the axis, the planes oriented parallel to each otherand spaced apart from each other along the axis, and wherein at leastone of the convex segments has one of the teeth coupled thereto, and atleast one of the concave segments has one of the teeth coupled thereto,and a distance between the spaced apart teeth defines a width of thepotato stick products, the width of resulting potato stick productsincluding at least one peak and at least one trough.
 2. The grate ofclaim 1, wherein adjacent ones of the teeth are spaced apart a width ina range of from about 0.04 inches to about 0.10 inches.
 3. The grate ofclaim 1, wherein the grate is configured to nest against a blade, theblade having a corresponding pattern of repeating convex segments andconcave segments.
 4. A blade and grate assembly for use in formingpotato stick products having a wavy cross-sectional shape, the blade andgrate assembly comprising: a blade holder having a plurality ofalternating convex segments and concave segments; a blade nested withthe blade holder, the blade having a plurality of alternating convexsegments and concave segments with a cutting edge that extends beyondthe convex segments and concave segments of the blade holder, thecutting edge of the blade further configured to form the wavycross-sectional shape of the potato sticks; a grate nested with theblade, the grate having a single, one-piece, unitary body with aplurality of alternating convex segments and concave segments extendingin a repeating pattern on an axis oriented along a length of the grate,defining a front side and a rear side, and aligned with the plurality ofalternating convex segments and concave segments of the blade, the gratehaving a plurality of spaced apart teeth extending in an upwarddirection and not in a downward direction from the plurality of convexsegments of the grate and the plurality of concave segments of thegrate, wherein each of the teeth has a fixed edge, a cutting edge, andan upper edge, the fixed edge coupled to one of the convex segments ofthe grate and the concave segments of the grate at the front side, thecutting edge being a free end disposed opposite the fixed edge, and theupper edge being a free end arranged between the fixed edge and thecutting edge, and each of the teeth is further aligned in one aplurality of planes that are oriented substantially perpendicular to theaxis, the planes oriented parallel to each other and spaced apart fromeach other along the axis, and wherein at least one of the convexsegments of the grate has one of the teeth coupled thereto, and at leastone of the concave segments of the grate has one of the teeth coupledthereto, and a distance between the spaced apart teeth defines a widthof the potato stick products, the width of resulting potato stickproducts including at least one peak and at least one trough; and aclamp securing the blade and the grate to the blade holder.
 5. The bladeand grate assembly of claim 4, wherein the potato stick products have awidth in a range of from about 0.04 inches to about 0.10 inches.
 6. Amethod of forming potato sticks having a wavy cross-sectional shape,comprising the steps of: providing a blade having a single, one-piece,unitary body with a plurality of convex segments and concave segments,each having cutting edges; nesting a grate with the blade, the gratehaving a plurality of convex segments and concave segments extending ina repeating pattern on an axis oriented along a length of the grate anddefining a front side and a rear side, in the nested position theplurality of convex segments and concave segments of the bladesubstantially align with the convex and concave segments of the grate,the grate including a plurality of spaced apart teeth extending in anupward direction and not in a downward direction from the plurality ofconvex segments of the grate and the plurality of concave segments ofthe grate, wherein each of the teeth has a fixed edge, a cutting edge,and an upper edge, the fixed edge coupled to one of the convex segmentsand the concave segments at the front side, the cutting edge being afree end disposed opposite the fixed edge, and the upper edge being afree end arranged between the fixed edge and the cutting edge, and eachof the teeth is further aligned in one a plurality of planes that areoriented substantially perpendicular to the axis, the planes orientedparallel to each other and spaced apart from each other along the axis,and wherein at least one of the convex segments has one of the teethcoupled thereto, and at least one of the concave segments has one of theteeth coupled thereto, a distance between the spaced apart teeth definesa width of the potato sticks; and urging one or more potatoes throughthe nested blade, grate and teeth such that the wavy potato sticks areformed, the width of resulting potato stick products including at leastone peak and at least one trough.
 7. The method of claim 6, wherein theblade is nested with the blade holder such that there is no appreciablespace between the blade and the blade holder.
 8. The method of claim 6,furthering including the step of installing the blade and the grate in acutting head assembly.